MFE O3 Design for Manufacture and Assembly

Answer key:
Section-I
1. Design for Manufacturing (DFM) is a methodology aimed at improving the
manufacturability or producibility of a single product by reducing manufacturing
costs
2. Functional dimension-is an important dimension that is involved with the
correct working of a machine assembly.
Non Functional dimension is, relatively, an unimportant dimension in that it is
not a critical dimension in the working of the machine.
3. This technique involves the selection of random observations with in the
simulation model. It is constrained for application involving random numbers to
solve deterministic and stochastic problems.
The underlying principle of this technique is
o Replace the actual statistical universe by another universe
described by some assumed probability distribution.
o Sample from this theoretical population by means of random
numbers.
4. Straightness, flatness, roundness, concentricity, squareness, parallelism,
angularity, symmetry
5. 1.trial and error 2. Interchangeable assembly 3.selective assembly
6. False
7. The procedure to be followed when changing the datum face may be
summarized thus:
o Decide the required manufacturing datum face.
o Decide the required manufacturing required manufacturing dimension
o Determine the tolerance for each of the manufacturing dimensions
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o Set suitable limits for all but of required dimensions

o Determine the limits for the final dimension.
8. True
9.

Uneconomical

Difficult to remove from the mould

Core removal difficulty

10. True
11. Machined holes

Round machined holes in a cast component may be produced by drilling

or reaming or by boring.

Drill/boring is decided by the size of the hole

Machined holes, up to and including 30mm diameter to be drilled, holes

over 30mm diameter to be bored.

Machined holes up to and including 30mm diameter to be cast solid.

Machined holes over 30mm diameter to be cast/ cored.

12.

Avoid placing welds in vulnerable cross-sections

Avoid laps, straps, and stiffening angles (with figures)

13. True
14. True
15.

-Economic analysis-component design

-Ability to identify uneconomical design
-Ability to modify the design to eliminate the fault whilst retain the

essential functional feature of the design

16.
unnecessary large machined areas
unnecessary amount of small tolerance machining
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 difficult or unduly lengthy machining features

slightly dissimilar components that could be standardized
17.

Six sigma is a business method for improving quality by removing defects

and their

causes in business process activities. it concentrates on

those outputs which are important to customers.

This method uses various statistical tools to measure business process.

The main goal is continuous improvement

Six

sigma

is

carried

out

as

project.(DMAIC-

Define,measure,analyze,improve and control)

Bottle-necks and problems identified.

Improvement program is defined and defects removed

18. A poka-yoke device is any mechanism that either prevents a mistake from
being made or makes the mistake obvious at a glance: to control (for instance
shuts down) or warn for abnormalities
No errors no defects Zero quality control (ZQC)
19. A team based approach to identifying and eliminating waste (non-valueadding activities) through continuous improvement by flowing the product at the
pull of the customer in pursuit of perfection
A methodology to minimize waste at all levels through assessment of
each activities of a company
20.
A Value Stream is the set of all actions (both value added and non value added)
required bringing a specific product or service from raw material through to the
customer.
Value Stream Mapping

Follow a product or service from beginning to end, and draw a visual

representation of every process in the material & information flow.

Then, draw (using icons) a future state map of how value should flow.

VSM serves as a - Communication Tool, Business planning Tool Tool to

manage any change process

Section-II
21.(i)

Tolerance must be placed on dimensions of a part to limit the

permissible variations in size because it is impossible to repeatedly
manufacture a part exactly to a given dimension.

A small tolerance results in greater ease of interchangeability of parts

and less play or chance for vibration in moving parts.

Obtaining the best quality and performance from the design.

Minimizing manufacturing cost.

Manufacturing process is a combination of three elements man,

materials and machine. If the process is under control,. All the
assignable causes of variation are controlled or eliminated, the
variations in sizes of similar components
will be within reasonable limits.

improves communication

provides better product design

increase production tolerance

Tolerances as Feature Attributes

Tolerance as an attribute
Size tolerance: attributes of dimension parameters
Form tolerance: attributes of edges or surfaces.
Position & orientation tolerance: attributes of feature relationships

21. (ii) Process capability analysis:

Statistical techniques can be helpful through the product cycle

Development activities prior to manufacture, in quantifying process

variability, in analyzing this variability relative to product requirements
or specifications, and in assisting development and manufacturing in
eliminating or greatly reducing this variability

Product capability refers to the uniformity of the process. Obviously, the

variability in the process is a measure of the uniformity of output.

There are two ways to think of this of this variability: 1.the natural or
inherent variability at a specified time; that is instantaneous
variability.2. The variability over time.

It is customary to take the 6-sigma in the distribution of the product

quality characteristic as a measure of process capability.

Process capability analysis as an engineering study to estimate

process capability.

The estimate process capability may be in the form of a probability

distribution having specified shape, center (mean), and spread
(standard deviation).

A process capability study usually measure functional parameter on

the product, not the process itself.

Process capability analysis is a vital part of an overall quality

improvement program.

Prediction how well the process will hold the tolerances.

Assisting product developers/designers in selecting or modifying

process.

Specifying performance requirements for few equipment.

Selecting between competing vendors.

Reducing the variability in a manufacturing process.

22. (i)

Interchangeability or random assembly is an assembly technique in

which all the components assemble with any other mating
components
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Selective assembly if the tolerance limit of mating part is very, in the

case of fully Interchangeability ,the demanded accuracy of assembly
may not be obtained. thus we go for selective assembly technique,
her all the parts are measured, graded and grouped according to size,
and finally corresponding groups are assembled together.

Interchangeability

Selective assembly

Mass production system.

Selective assembly where parts are

Specified tolerance limits.

manufactured

to

rather

wider

Process cability is equal to or less tolerances.

than

manufacturing

tolerance Only matched groups of mating parts

allowed for that part.

are assembled

Assembly time is reduced

Reduced production cost

(ii) Laminated shim control of axial ply.

Larger component machining tolerance, when a critical assembly is

requested, is the laminated shim.

This particular type of shim has the advantage of quickly and a accurately
providing this assembly requirements No second stage machining is
involved.

Only one shim is needed per unit assembly, thus providing an advantage
over other shim system where a range of several shim thickness must be
available.

Laminated shins sheet of brass fail.

The choice of lamination thickness, either 0.051mm or 0.076 mm is

usually determined by assembly tolerance involved, thus.
o If the assembly tolerance is 0.051mm laminations, use 0.51mm
lamination
o If the assembly tolerance is 0.076 mm or more, use 0.076 mm
lamination.

Min thickness can vary depending upon the overall size and shape of
the shim used.

Benefits of laminated shim.

Replace costly precision machining of making parts.

Provide flexibility for assembly line adjustments.

Make assembly line adjustments earlier and faster.

Smart shim with feel able precision of 0.001 mm is readily offered.

23. Grouped Datum plane, Spigot and hole assembly with grouped Datum plane,
recess and pin (with figure)

Function:
The system controls the relative movements of two components in all 6

degrees of freedom, but rotation about 0Z less precisely than the others.
This system is used mainly as a datum group for positional features.

Geometric analysis:
The plane are principal datums with zero position tolerances.
The spigot and ranges are datum with zero position and square ness
tolerances on MMc relative to the principal datum.

The hole and pin are datum having position and square ness tolerance
MMc relative to the datum spigot and plane and the datum spigot and
plane and the datum recess and plane.

Location accuracy:
Translational movement in the x,y and z direction is limited by the fit c

between the spigot and recess and by the flatness of the planes. Take as before
the Criterion.
C=Ck

Rotation about ox and oy is limited by the flatness of the planes, about oz

by the fit between the spigot and recess and the hole and pin.

The clearance between the latter including provision for position tolerance for
the position tolerances for hole and pin.

Basic size:
Choose from data sheets as appropriates.

Fits, design sizes and tolerance. The fit between the spigot and recess
should be chose n to suit the location accuracy required.

Hole basis is preferred.

Do not specify flatness tolerances for the planes unless unusually location
is required.

24. (i) Comparison between geometric tolerancing and coordinate tolerancing

Drawing concept
Coordinate tolerancing
Tolerance
zone Condition
shape

Square

or

geometric tolerancing
Condition

rectangular Can use diameter symbols

zones for hole location

to allow round tolerance

zones

result
result
less tolerance available for 57% more tolerance for
hole
Tolerance
flexibility

hole location

higher mfg costs

zone Condition
Tolerance zone fixed in size

Lower mfg costs

Condition
Use

of

modifier

allows

tolerance zone to increase

under certain conditions

result
Functional parts scrapped

result
Functional parts used

Higher operating costs

Lower operating costs

24.(ii) Projected Tolerance Zone (with figure)

 When dimensioning threaded holes (or press-fit holes), consideration must

be given to the variation in perpendicularity of the axis of the hole relative
to the mating face of the assembly.
The squareness error of the fastener (or press-fit pin) may result in an
interference condition with the mating part.
Where design considerations require a closer control in the perpendicularity of a
threaded hole than that allowed by the positional tolerance, a perpendicularity
tolerance applied as a projected tolerance zone may be specified
Specifying a projected tolerance zone will ensure that fixed fasteners do
not interfere with mating parts
Further enlargement of clearance holes to provide for an extreme variation
in perpendicularity of the fastener is not necessary.
Zero true position tolerancing

Zero true position tolerancing is a

technique adaptable to situation

requiring functional interchangeability and maximum tolerance advantage

in the feature size,form and position interrelationships.

Where mating parts and features are simply to mate up or GO and

tangent contact of the mating features could occur, zero tolerancing is
technically acceptable

Zero position tolerancing is not appropriate

True position tolerances are usually established on the basis of MMC size
relationships of mating part features.

In zero true position tolerancing the same principles apply, except that the
true position tolerancing stated is always a fixed zero, with all the
tolerance placed on the same dimension.

25. (i) (i) Form design for welding rules: (with fogures)

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Do not attempt to copy blindly from cast, riveted, and forged designs.

Provide for s straight line force pattern as far as possible

Avoid laps, straps, and stiffening angles

Use butt welds wherever possible

Limit the number of welds used

Make sure that ends to be welded together are of equal thickness

Avoid placing welds in vulnerable cross-sections.

Facilitate assembly by means of registers, shoulders,etc

Provide for easy ass to welds.

Allow for the effect of thermal stress

Distribute heavy loading over long welds in the longitudinal direction

Avoid subjecting welds to bending loads

be careful with the use of ribs

avoid large flat walls which tent to bulge and flex

25.(ii) cast holes-cored holes(with figures)

o Holes of any kind in castings are produced either by casting or by
coring.
o Holes produced by the mould sand of the boxes are cast holes.
o Holes produced by use of special sand core cored holes
26 (i). Identifying uneconomical design features
unnecessary large machined areas
unnecessary amount of small tolerance machining
difficult or unduly lengthy machining features
slightly dissimilar components that could be standardized
machined features restricted to one particular process
feasibility of assembly and dismantling
for casting, sand cores that may be eliminated

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(ii) Modifying the desig

when redesign for manufacture the external features and dimensions of

the unit should remain unaltered

Internal features may be adjusted in any way to meet manufacturing

requirements, provided the functional features of the design are not
impaired.

Provided the functional features of the design are not impaired

Whenever an assembly or dismantling difficulty is present in a proposed

design it is essential that difficulty be removed, even expensive.

27. Gear box: Identifying uneconomical design features

unnecessary large machined areas
unnecessary amount of small tolerance machining
difficult or unduly lengthy machining features
slightly dissimilar components that could be standardized
machined features restricted to one particular process
feasibility of assembly and dismantling
For casting, sand cores that may be eliminated.
Base has an unnecessarily large machine area
With base as mould parting line, internal and external sand cores
needed for the circular bosses.
Spot facing of holding down bolt holes restricts machining to one
processes
Joint face has unnescessarily large machined area
Different types of bearing bush
Different type of boss type
Assembly of layshaft is difficult
Acceptable modified design of the spur gear reduction unit where (with figure)

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The machined base is reduced to small facings encompassing the

holding down bolt holes

The casting can be obtained without the need for sand cores

The holding down bolt hole bosses can be machined by several

different processes

One type of bearing bush used throughout

Splitting the box on the shafts axis permits easy/dismantling, and

hence permits

Amalagamation of gears with shafts which eliminate an appreciable

amount of small tolerance machimg-circlips and keys.

28. (i)
DFMA Applications

DFMA software provides a systematic procedure for analyzing proposed designs

from the point of view of assembly and manufacture.

This procedure results in simpler and more reliable products that are less
expensive to assemble and manufacture.

In addition, any reduction in the number of parts in an assembly produces a

snowball effect on cost reduction, because of the drawings and specifications
that are no longer needed, the vendors that are no longer required, and the
inventory that is eliminated

DFMA tools encourage dialogue between designers and the manufacturing

engineers and any other individuals who play a part in determining final product
costs during the early stages of design

This means that team working is encouraged, and the benefits of simultaneous
or concurrent engineering can be achieved.
Application of DFMA Software to the Design of a Motor-Drive Assembly

Application of DFMA at an Electronics Manufacturer

Design-for-Assembly Implementation at an Automotive Manufacturer

Manufacturability Benchmarking by an Automotive Manufacturer

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(ii) Quality Function Deployment

A Means of integrating the design process

Voice of the Customer

Priorities of Marketing

Product design knowledge of the Engineer

(Production Planning and Design)

House of Quality

Gather customer attributes

Group attributes logically

Assess relative importance of the attributes

Assess competitive performance on the attributes

Describe product in terms of engineering characteristics

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Detail influence of engineering characteristics on customer attributes

Detail interaction between engineering characteristics

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